technical presentation - hugo provencher · 09/09/2013 technical presentation 2 agenda 1.background...
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Technical Presentation
Presented By: Hugo Provencher
09/09/2013 Technical Presentation 2
Agenda
1.Background2.Solar Car Overview3.EcoCAR
• Overview• Model-based design• HV System• Results
4.Other Projects• Matlab GUI• Work at GM
5.Q & A
09/09/2013 Technical Presentation 3
Background
Bachelor degree in
focus on Power Systems
Bachelor degree inElectrical Eng.
focus on Power Systems
2005 2010 2012 End of 2013
Master’s degree in
High Voltage
Master’s degree inAutomotive Eng.
focus EV Controls & High Voltage
Solar Car #1
Solar Car #2
EcoCAR Y2
EcoCAR Y3
Controls Eng. at GM
GM /Hybrid Vehicle
ControlsGM /
Advanced Chassis
Ctrl & HV Lead
AssistantCtrl & HV
Lead
Ctrl Lead
Ctrl & HV Lead Calibrator
Ctrl Lead for 1 ATW
project
Montreal Toronto
2009 2011
24/02/2016 Technical Presentation 4
Background
System Eng. In
Transportation
System Eng. InPower Electronics at
Bombardier Transportation
End of 2013 Today
High Voltage and Controls Eng. inElectric Vehicle at
Lion Bus
Auxiliary Power Supply
BART Project
Auxiliary Power Supply Equipment for the
BART Project
eLion Electric School Bus
System Eng.
Electric Vehicle Technical Lead
Montreal
Mid 2015
09/09/2013 Technical Presentation 5
Solar Car Overview
The Technology• 84 Li-ion cells in 6 modules• 5 kWh total capacity (LTC, now Gaia)• Air-cooled• 1.5 kW wheel motor (BionX)• 25 kW motor controler (Tritium)
Skills Acquired• EV knowledge• High voltage systems• Hands-on• CAN• C code• Circuit and PCB design• Presentation
Darwin
Adelaide
World Solar Challenge 2007 and 2009
09/09/2013 Technical Presentation 6
C code / PCB
Vehicle Integration Module• C code• Circuit design• PCB design• Integrated into carbon fiber
steering wheel
09/09/2013 Technical Presentation 7
Solar Car Overview
09/09/2013 Technical Presentation 8
EcoCAR
Vehicle Integration Module
HV distribution box
Front ESS Thermoelectric unit
12V distribution box
Underside ESS Thermoelectric unit
Dc/Dc
09/09/2013 Technical Presentation 9
ESS Refinement
Year 2 Design• 84 Cells in 6 modules• 75 kWh total capacity• Air-cooled• Located in rear
passenger compartment
Final Design• 94 Cells in 2 modules• 84 kWh total capacity• Liquid-cooled• Located in engine compartment &
underside of vehicle
09/09/2013 Technical Presentation 10
Motor / Motor Controller
Motor• Located in the engine bay• S10-EV :
102 kW 3-phase electric motor
Motor Controller• Located in the engine bay• Input:
80-400 Vdc• Output:
160 kW max 266 Arms 0-500 Hz
09/09/2013 Technical Presentation 11
HV System
Year 2 Design• Located throughout vehicle• Majority of functions performed with
hardware• Location of hardware caused wiring to
run throughout vehicle
Final Design• Located within front ESS• Finite State Machine within MATLAB
used to control HV system• All HV components located within front
cradle. All HV contactors, fuses, and GFI integrated into front ESS enclosure.
09/09/2013 Technical Presentation 12
HV Schematic
09/09/2013 Technical Presentation 13
Veh. Integration Module / Chargers
Vehicle Integration Module• All Mototron code written in
MATLAB Simulink due to it’s simplicity.
• Woodward Mototron ECM5554 used as ECU
Chargers• Two more BRUSA chargers were
added to increase charging capacity to 16.5 kWh (previously 9.9 kWh)
2 additional chargers
3 chargers
09/09/2013 Technical Presentation 14
MotoTron / Veh. Integration Module
09/09/2013 Technical Presentation 15
GM / MicroAutoBox / Simulink
Confidential
09/09/2013 Technical Presentation 16
Extrapolated Test Results - With Regenerative Braking
• Total Range: 268 miles (430 km)• Average Energy Consumption: 3 288 Wh/mi (179 Wh/km)• Average City MPGGE: 117.2 (2.0L/100km)• Regenerative braking improved city MPPGE by 30% based on UDDS
test cycle
EPA Testing Results
09/09/2013 Technical Presentation 17
Matlab Data Import/Sim. Tool
09/09/2013 Technical Presentation 18
GM / Research Project
Confidential
09/09/2013 Technical Presentation 19
Thank you for your attention
Q & A
09/09/2013 Technical Presentation 20
Backup
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Detailed DesignDetailed Design
4
09/09/2013 Technical Presentation 24
HIL / CAN / Simulink / Controler
09/09/2013 Technical Presentation 25
Vehicle Architecture
Lithium Polymer (Li-Poly) CellsDrive Unit: 110 kW, GM S10-EV motor
Type: Full Function Electric Vehicle (FFEV)
90 kWh of Batteries: Dow Kokam, 240 AHElectric Motor: Delphi S10-EV, 110 kW (150 hp)Traction Inverter Drive: MES-DEA, TIM 600
09/09/2013 Technical Presentation 26
ESS Refinement-Cont’d
Temperature SensorCoolant Block
Voltage Sensor
Positive Terminal
Negative Terminal
• BMS Control using REAP System• Each cell has voltage sensor• Every 2 cells has temperature sensor• BMS units actively balance the pack as it charges and discharges
Liquid Cooling System
• Each frame has cooling tube • Coolant plate every second frame• 50% water 50% glycol mixture• Thermoelectric units used for heating/cooling liquid
Battery Monitoring
09/09/2013 Technical Presentation 27
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